The Vintage Aviator - Fokker DVIIhttp://thevintageaviator.co.nz/taxonomy/term/47
enHistoryhttp://thevintageaviator.co.nz/projects/fokker-dvii/blue-max
<div class="field field--name-body field--type-text-with-summary field--label-hidden"><div class="field__items field-items"><div class="field__item field-item even" property="content:encoded"><p class="big-quote"><span class="big-letter-quote">“T</span>he 1914-1918 Aviation Heritage Trust also owns two other aircraft used in “the Blue Max” both Pfalz D.III’s. Currently one of these is painted in the colors of Leutenant Fritz Hohn, who flew with Jasta 21 and ended the war with 21 victories.<strong>”</strong></p>
<h3 class="rtejustify">The Blue Max</h3>
<h4 class="rtejustify"><strong><em>Colin Owers</em></strong> has done some research into the history of this and other Movie Planes;</h4>
<p class="rtejustify"><a href="http://thevintageaviator.co.nz/sites/default/files/images/fokker-dvii/bluemax_poster.jpg" class="colorbox embedded-image" rel="content-images" title="&lt;p&gt;Original poster by Frank McCarthy.&lt;br /&gt;&#10;From the &lt;a href=&quot;http://en.wikipedia.org/wiki/The_Blue_Max&quot;&gt;Wikipedia &quot;The Blue Max&quot; movie page&lt;/a&gt; &lt;/p&gt;&#10;" style="float:right"><img alt="" id="image-2986-medium" src="/sites/default/files/styles/medium/public/images/fokker-dvii/bluemax_poster.jpg" style="float:right" /></a><br />
T<strong>he Allied observer’s attention is drawn away from the frontline as two black specks fast approaching his hydrogen filled balloon resolve into a Pfalz D.III and a Fokker D.VII. Their machine guns spitting fire, the two German fighters dive onto the balloon as its hapless crew try and winch it down to safety.</strong> The observer takes to his parachute just before the envelope explodes in flames. Fleeing from their victory the Germans are set upon by a flight of British S.E.5a scouts seeking revenge. </p>
<p class="rtejustify">This description could have been of an action over the Western Front in1918, however, in actuality, it took place in Irish skies in 1965. The announcement that 20th Century Fox had purchased the film rights of Jack D Hunter’s “<a href="http://en.wikipedia.org/wiki/The_Blue_Max">The Blue Max</a>” sent shivers of anticipation through the World War I aviation community. The last Hollywood attempt at a WWI aviation movie was the dismal “Layafette Escadrille” by William Wellman. While including some good scenes of training on Bleriots, this Tab Hunter vehicle borrowed the dog fight sequence from his earlier ”Men with Wings.” The “Blue Max” film was to be a multi-million dollar production with an all star cast. Blond, blue eyed George Peppard played the anti-hero Bruno Stachel. James Mason, Jeremy Kempe and Ursula Andress filled out the star studded cast. The real stars were to be the full sized reproductions of World War I fighters constructed for the film- two Pfalz D.III biplanes, two Fokker Dr.I triplanes, two S.E.5a scouts and three Fokker D.VII biplanes. The aerial sequences were fleshed out with Stampe SV-4C two-seaters converted to single-seat “fighters”. They wore German or British camouflage as appropriate for their scene. A modified Caudron 276 Luciole was an Allied reconnaissance machine. Mock-ups appeared in the ground scenes and as ”crashed” aircraft.</p>
<h3 class="rtejustify">Reproductions in a hurry</h3>
<p class="rtejustify">T<strong>he reproductions had to be built in a hurry to meet the time frame for shooting and were constructed in different locations. </strong>Miles Marine and Structural Plastics Ltd of Shorham, constructed the steel tube fuselage S.E.5a reproductions. With a 200 hp De Havilland Gypsy Queen 3 engine installed, they were very manoeuvrable and reportedly easy to fly. John Bitz GmbH of Munich built the Dr.I triplanes (G-ATIY and G- ATJM) around Simens radial engines, as a result the machines lack the finesse of the actual Fokker machines. One Pfalz D.III reproduction each was constructed by Personal Plane Services (G-ATIF) and the other by the Hampshire Aero Club (G-ATIG).</p>
<p class="rtejustify"><a href="http://thevintageaviator.co.nz/sites/default/files/images/fokker-dvii/bluemax15-1200x822.jpg" class="colorbox embedded-image" rel="content-images" title="&lt;p&gt;The two Pfalz at Weston during filming of &quot;Darling Lili&quot;&lt;/p&gt;&#10;" style="float:left"><img alt="" class="float:left;" id="image-2988-medium" src="/sites/default/files/styles/medium/public/images/fokker-dvii/bluemax15-1200x822.jpg" style="float:left" /></a><br />
At Dinard airport in France, Claude Rousseau constructed three Fokker D.VII fighters (F-BNDF to F-BNDH) in six months. At the time it was stated that the machines were constructed to original plans and dimensions. The limited choice of engines led to the Gypsy Queen being also installed in the D.VII reproductions. The Gypsy Queen is a six cylinder in-line inverted air-cooled direct-drive engine, as a result the prop emerges through what would be the radiator shell of a true D.VII. Rousseau Aviation named the reproduction the D.VII-65.<br /><br />
<br />
</p>
<h3 class="rtejustify">Aircraft in the Movies</h3>
<p class="rtejustify">T<strong>he availability of these aircraft would see them appearing in more movies. “Darling Lili” of 1970 was a vehicle for Rock Hudson and Julie Andrews.</strong> <strong>A musical comedy, it was memorable in one aspect, the building of six S.E.5a reproductions added to the Allies squadron.</strong> These were based on the Currie Wot airframe and were referred to as Minis due to their not being full size reproductions. Appearances in “You Can’t Win them All”, “Von Richtofen and Brown” (aka “The Red Baron”), and “Zeppelin”, followed. The latter two movies saw fatal crashes and the aircraft were soon after dispersed to private collections.<br />
</p>
<p class="rtejustify"><a href="http://thevintageaviator.co.nz/sites/default/files/images/fokker-dvii/dviiweston.jpg" class="colorbox embedded-image" rel="content-images" title="&lt;p&gt;Charles Boddington in the &quot;Blue Max&quot; Fokker DVII during Filming at Weston&lt;/p&gt;&#10;" style=""><img alt="" id="image-2989-preview" src="/sites/default/files/styles/screensize/public/images/fokker-dvii/dviiweston.jpg" /></a></p>
<div>
<div> </div>
<div> </div>
</div>
<p> </p>
<div>
<div> </div>
<div> </div>
</div>
<p> </p>
</div></div></div><div class="field field--name-field-tags field--type-taxonomy-term-reference field--label-above"><div class="field__label">Tags:&nbsp;</div><div class="field__items field-items"><div class="field__item field-item even" rel="dc:subject"><a href="/taxonomy/term/47" typeof="skos:Concept" property="rdfs:label skos:prefLabel" datatype="">Fokker DVII</a></div></div></div>Mon, 26 May 2014 07:12:53 +0000steve251 at http://thevintageaviator.co.nzFokker DVII Build Storyhttp://thevintageaviator.co.nz/unpublished/fokker-dvii/fokker-dvii-build-story
<div class="field field--name-body field--type-text-with-summary field--label-hidden"><div class="field__items field-items"><div class="field__item field-item even" property="content:encoded"><p class="rtejustify"><a href="http://thevintageaviator.co.nz/sites/default/files/images/fokker-dvii-build/blue-max-build-001.jpg" class="colorbox embedded-image" rel="content-images" title="Blue Max Build 001" style="float:right;"><img align="right" src="/sites/default/files/styles/medium/public/images/fokker-dvii-build/blue-max-build-001.jpg" id="image-2990-thumbnail" alt="" /></a><br /><span class="dropcap">T</span><b>here are as many reasons for taking on a project as there are methods to complete it. In the case of movie props... one source is the original article, another is to build a replica. </b><b>Time constraints and deadlines sometimes dictate the style and construction methods.</b> In the case of the Fokker DVII built for “The Blue Max” film. We can safely say the aircraft was built to an airworthy standard in a very short period of time! At the Vintage Aviator Ltd we are responsible for the operation and maintenance of a number of WW1 aircraft, including the Fokker DVII built in France for the 1966 film “The Blue Max”. The original constructors of this machine, Rousseau Aviation, Dinard Airport France, did a marvelous job at creating a flying aircraft replica for the film, however years of use and several owners later have taken it’s toll. This aircraft was airworthy when it arrived here in New Zealand but we wanted to restore it and add more details that would make it a more accurate replica.</p> <p class="rtejustify">After having flown the DVII for several hours here in NZ we became aware of its shortcomings rather quickly, it just didn’t perform like the legendary fighter it represented. The airplane was heavy and the engine seemed a bit tired and the fabric covering was clearly a quick attempt at “fake” printed lozenge. Each pilot that had the chance to fly it liked it, but all made the same general comments “It feels heavy”, “It wont climb”, and “I cant catch the SE.5a or the Camel”...</p> <h3 class="rtejustify">Face Lift</h3> <p class="rtejustify"><span class="dropcap">T</span><b>he decision was quickly made to give the DVII a bit of a face lift. After all of our airshow commitments had passed we started to disassemble the aircraft and see what could be done to improve its performance and looks. </b>Since this airplane is a replica that doesn’t use an original engine nor original construction we had a great deal of leeway on what we could do.<br /><br /><a href="http://thevintageaviator.co.nz/sites/default/files/images/fokker-dvii-build/blue-max-build-002.jpg" class="colorbox embedded-image" rel="content-images" title="Lower wing undergoing inspection and repair" style="float:left;"><img align="left" src="/sites/default/files/styles/medium/public/images/fokker-dvii-build/blue-max-build-002.jpg" alt="" id="image-2991-medium" /></a><br />In all fairness to the original constructors, this aircraft has been around for a while and has been used in several films, it served it’s purpose and did a fantastic job. The sheer fact the airplane has been in service for nearly 45 years could add to it’s lack of performance, propellers have been changed, the engine was starting to get tired, repairs have been made and the airframe was getting heavier as planes seem to do when they age! With the dismantled aircraft in our workshop we could remove the fabric and inspect all of the individual components. The construction slightly different to the original, ribs are made of thin plywood and the spars appear to be solid laminated lengths of spruce. The trailing edge has been cut out of timber rather than the original wire trailing edge that gives many Fokker aircraft that distinctive “scalloped” look. Wing tip bows are made of massive chunks of ash that have been steamed to shape them. In an effort to make sure this aircraft was back in the air before too long we set a deadline to “return it to service” so that we didn’t end up rebuilding everything or spending too much on it! It was quickly determined that the wings were in good shape and only minor repairs were needed. We removed some weight from the wingtip bows and sealed the entire structure to protect it from moisture.<br /><br /><br /> </p> <h3 class="rtejustify">Materials</h3> <p class="rtejustify"><a href="http://thevintageaviator.co.nz/sites/default/files/images/fokker-dvii-build/blue-max-build-016.jpg" class="colorbox embedded-image" rel="content-images" title="This heavy construction was replaced with 4130 streamlined tube at a huge weight savings" style="float:right;"><img align="right" src="/sites/default/files/styles/medium/public/images/fokker-dvii-build/blue-max-build-016.jpg" alt="" id="image-2998-thumbnail" /></a><br /><span class="dropcap">W</span><b>hen building any aircraft raw materials are of prime importance. The selection of materials based on strength weight and availability.</b> It became apparent that during the construction of the DVII the selection of materials to build the aircraft out of must have been strongly influenced perhaps dictated by the time frame. For instance the decision to make “streamlined tube” out of several round tubes had to have been because the builders could not source appropriate sized streamlined tube in a hurry. This method of construction added a huge amount of weight to the plane and was far more labor intensive. The cabane strut “tripods”, interplane struts and landing gear struts were all built up of many pieces of tubing rather than single streamlined tubes. These make shift streamlined tubes were built up of at least two whole round tubes of different sizes and then tacked together with two more sections of round tube split in half! Each conglomerate of steel tubing was then wrapped with fabric to give it a finished streamlined airfoil shape. These parts alone were several times heavier than a similar part made out of a single sreamlined tube. In order to replace these built up struts we positioned the overhauled wings in place on the fuselage and rigged the airplane, partially fabricating the new struts in situ. </p> <p class="cleared rtejustify" style="clear: both;"><a href="http://thevintageaviator.co.nz/sites/default/files/images/fokker-dvii-build/blue-max-build-089.jpg" class="colorbox embedded-image" rel="content-images" title="&lt;p&gt;Newly recovered fuselage, note the printed fabric rather than the painted on lozenge it previously had.&lt;/p&gt;&#10;" style=""><img alt="" src="/sites/default/files/styles/screensize/public/images/fokker-dvii-build/blue-max-build-089.jpg" id="image-3030-preview" /></a></p> <h3 class="rtejustify"><br />Remaking Authenticity</h3> <p class="rtejustify"><a href="http://thevintageaviator.co.nz/sites/default/files/images/fokker-dvii-build/blue-max-build-015.jpg" class="colorbox embedded-image" rel="content-images" title="&lt;p&gt;Just some of the parts removed or replaced, A total of nearly 400 lbs was removed!&lt;/p&gt;&#10;" style="float:left;"><img align="left" src="/sites/default/files/styles/medium/public/images/fokker-dvii-build/blue-max-build-015.jpg" alt="" id="image-2997-thumbnail" /></a><br /><span class="dropcap">T</span><b>he tail surfaces were also constructed out of materials that deviated a great deal from the original.</b> Since many sets of drawings and much research has been made into the Fokker construction it would be foolish to imply the builders were simply not aware of the original construction. The original constructors also mentioned that they had access to one of the surviving original Fokker DVII’s housed in the French Musee de l’Air at Chalais Meudon. Once the tailplane was stripped of fabric we decided to see why it was so heavy. We have already restored seven Fokker Triplanes and have a tremendous experience with Fokker tailplanes. The DVII tailplane just felt wrong! The easiest way to check the material would be to cut into it and see how thick the steel tube was....... after one slice we discovered it was more like pipe!</p><p class="rtejustify"><a href="http://thevintageaviator.co.nz/sites/default/files/images/fokker-dvii-build/blue-max-build-018.jpg" class="colorbox embedded-image" rel="content-images" title="David Cretchley weighing the ballast we removed from the nose of the aircraft" style="float:right;"><img align="right" src="/sites/default/files/styles/medium/public/images/fokker-dvii-build/blue-max-build-018.jpg" alt="" id="image-2999-thumbnail" /></a><br />This would explain the huge lead weights attached to the engine mount, these were needed to counterbalance the heavy tail and maintain a reasonable center of gravity. We were shocked when we removed the weights and set them on our scales. The two weights totaled nearly two hundred pounds! Part of this was necessary to compensate for using a lighter more modern air cooled engine, a gipsy queen, instead of the heavier liquid cooled Mercedes engine which would have originally been used.</p> <p class="rtejustify"><a href="http://thevintageaviator.co.nz/sites/default/files/images/fokker-dvii-build/blue-max-build-094.jpg" class="colorbox embedded-image" rel="content-images" title="New tailskid replaced the modern tailwheel that was fitted" style="float:left;"><img align="left" src="/sites/default/files/styles/medium/public/images/fokker-dvii-build/blue-max-build-094.jpg" alt="" id="image-3034-thumbnail" /></a><br />A new tailplane was in order, some parts were reused and incorporated into our new chromoly structure. While we were working on the tail section we decided to install a proper tailskid in place of the tailwheel that was fitted. We knew that a tailskid must have been installed when the airplane was built, it appeared in the film with one, and all the mounting points and bungee attachments were already in place. Fitting a tailskid was easy.</p> <h3 class="rtejustify">Structure</h3> <p class="rtejustify"><a href="http://thevintageaviator.co.nz/sites/default/files/images/fokker-dvii-build/blue-max-build-036.jpg" class="colorbox embedded-image" rel="content-images" title="The entire fuselage was sandblasted inspected and repainted" style="float:right;"><img align="right" src="/sites/default/files/styles/medium/public/images/fokker-dvii-build/blue-max-build-036.jpg" alt="" id="image-3011-thumbnail" /></a><br /><span class="dropcap">M</span><b>oving forward from the tail, we found the structure to be well preserved and in incredibly good condition, </b>all that was required was stripping the paint and removing some unnecessary turnbuckles. The Fokker style fuselage is of welded steel construction, having wire bracing in each “bay”. In this replica each wire brace had two turnbuckles, we elected to liberate some of these turnbuckles for future use elsewhere and to reduce weight once again. The steel structure was stripped and repainted and all new hardwire bracing installed with half as many turnbuckles. The floorboards were heavy old oil soaked fiberboard that was beginning to delaminate so we replaced these with aircraft plywood and thin aluminum “heel plates” to help prevent the wood from wearing away. The seat, control stick assembly and rudder bar was a complete unit removed from a Stampe biplane, this unit was restored and reinstalled after minor modification to the brake master cylinders.</p> <p class="cleared rtejustify" style="clear: both;"><a href="http://thevintageaviator.co.nz/sites/default/files/images/fokker-dvii-build/blue-max-build-040.jpg" class="colorbox embedded-image" rel="content-images" title="Luckily we had an original Mercedes engine to copy details from" style=""><img src="/sites/default/files/styles/screensize/public/images/fokker-dvii-build/blue-max-build-040.jpg" alt="" id="image-3014-preview" /></a></p> <h3 class="rtejustify"><br />Accessories</h3> <p class="rtejustify"><a href="http://thevintageaviator.co.nz/sites/default/files/images/fokker-dvii-build/blue-max-build-095.jpg" class="colorbox embedded-image" rel="content-images" title="&lt;p&gt;Engine details complete, the new gun m ounts are ready to recive replica &lt;a href=&quot;/projects/reproduction-guns/spandau-gun&quot;&gt;spandau&lt;/a&gt;'s&lt;/p&gt;&#10;" style="float:right;"><img align="right" src="/sites/default/files/styles/medium/public/images/fokker-dvii-build/blue-max-build-095.jpg" alt="" id="image-3035-medium" /></a><br /><span class="dropcap">I</span><b>n an effort to make the DVII look more authentic we installed a set of our reproduction aircraft guns</b><b>, in this case LMG 08/15 “Spandau” machine guns. </b>We removed the makeshift windscreen and added ammo chutes, fuel gauge, fuel filler and various doors and access panels that an original aircraft would have. Again to our amazement, this airplane had a huge fuel tank entirely made out of steel turn plate, it weighed a ton. We decided to make a lighter aluminum tank with a slightly smaller volume, this even gave the pilot more room for his legs.</p> <p class="rtejustify"><a href="http://thevintageaviator.co.nz/sites/default/files/images/fokker-dvii-build/blue-max-build-045.jpg" class="colorbox embedded-image" rel="content-images" title="&lt;p&gt;The finished fiberglass nose, ready for paint&lt;/p&gt;&#10;" style="float:left;"><img align="left" src="/sites/default/files/styles/medium/public/images/fokker-dvii-build/blue-max-build-045.jpg" alt="" id="image-3019-medium" /></a><br />Forward of the firewall we focused our efforts on cleaning up plumbing and wiring since the engine installation was functional and in fairly good order. Upon inspection only a few brackets showed distress form years of service, these were repaired by welding or replaced and the newly overhauled Gipsy queen set in place so that new cowlings could be made. The replica already had slightly modified cowls to hide the modern engine and disguise it looks, these could be improved on. We chose a late model Fokker Built aircraft to replicate, this necessitated making new cowlings with proper louvers and a reshaping of the fiberglass nose bowl. </p> <p class="cleared rtejustify" style="clear: both;"><a href="http://thevintageaviator.co.nz/sites/default/files/images/fokker-dvii-build/blue-max-build-043.jpg" class="colorbox embedded-image" rel="content-images" title="&lt;p&gt;The finished Gipsy / &lt;a href=&quot;/projects/mercedes-engine/mercedes-engine-restoration&quot;&gt;Mercedes&lt;/a&gt; engine&lt;/p&gt;&#10;" style="float:left;float: left;"><img align="left" src="/sites/default/files/styles/medium/public/images/fokker-dvii-build/blue-max-build-043.jpg" style="float: left;" alt="" id="image-3017-thumbnail" /></a><a href="http://thevintageaviator.co.nz/sites/default/files/images/fokker-dvii-build/blue-max-build-044.jpg" class="colorbox embedded-image" rel="content-images" title="Fitting new side cowls and fokker style wingnuts" style="float:left;float: left;"><img align="left" src="/sites/default/files/styles/medium/public/images/fokker-dvii-build/blue-max-build-044.jpg" alt="" id="image-3018-thumbnail" style="float: left;" /></a><a href="http://thevintageaviator.co.nz/sites/default/files/images/fokker-dvii-build/blue-max-build-084.jpg" class="colorbox embedded-image" rel="content-images" title="The working exhaust made to look just like the Mercedes exhaust stack" style="float:left;float: left;"><img align="left" src="/sites/default/files/styles/medium/public/images/fokker-dvii-build/blue-max-build-084.jpg" alt="" id="image-3027-thumbnail" style="float: left;" /></a></p> <h3 class="rtejustify">Heavy Steel Landing Gear</h3> <p class="rtejustify"><br /><a href="http://thevintageaviator.co.nz/sites/default/files/images/fokker-dvii-build/blue-max-build-029.jpg" class="colorbox embedded-image" rel="content-images" title="&lt;p&gt;Very sturdy and quickly built parts show access holes cut with a torch!&lt;/p&gt;&#10;" style="float:right;"><img align="right" src="/sites/default/files/styles/medium/public/images/fokker-dvii-build/blue-max-build-029.jpg" alt="" id="image-3004-thumbnail" /></a><span class="dropcap">T</span><b>he last major item to overhaul was the landing gear. Like everything else, this was </b><b>heavy and made of steel. </b>Original Fokker landing gear was carefully designed to be both strong and lightweight. Instead of the original style riveted aluminum box section this landing gear was made of Steel with access holes cut with a torch! Now it may not have been pretty but it sure worked well. The entire landing gear and axle assembly was replaced and as a result a weight savings of nearly sixty pounds was realized. After building the more authentic Fokker style landing gear one could see why a simpler version was used, the aluminum box section was difficult to construct and certainly took much longer than the simple welded version, and in the end it is completely hidden by the large fairing between the wheels.</p><p class="rtejustify"><a href="http://thevintageaviator.co.nz/sites/default/files/images/fokker-dvii-build/blue-max-build-039.jpg" class="colorbox embedded-image" rel="content-images" title="New landing gear assembly built to Fokker drawings" style="float:left;"><img align="left" src="/sites/default/files/styles/medium/public/images/fokker-dvii-build/blue-max-build-039.jpg" alt="" id="image-3013-thumbnail" /></a></p><p class="rtejustify">Only with a replica aircraft could we have the leeway to experiment with restoration and reconstruction on this level. However, with the time constraints involved, TVAL had to discover methods of reconstruction that wouldn’t involve total rebuilding and painstaking hours of work. With the overall facelift that the Fokker DVII received, including quite a drastic weight loss with the tailplane, fuel tank and landing gear replaced, we became confident that this would increase the aircraft’s performance in the sky, not to mention more leg-room for the pilot! Now with brand new Spandau guns and printed fabric replacing the previous painted lozenge, the new Fokker DVII is surely close to it’s former glory as a renowned fighter of speed and maneouverability, surely capable of once again catching the Se5a and the Camel.</p> <p><br /> </p><p> </p> <p class="cleared rtejustify" style="clear: both;"><a href="http://thevintageaviator.co.nz/sites/default/files/images/fokker-dvii-build/blue-max-build-091.jpg" class="colorbox embedded-image" rel="content-images" title="Upper wing fitted" style=""><img src="/sites/default/files/styles/screensize/public/images/fokker-dvii-build/blue-max-build-091.jpg" alt="" id="image-3032-preview" /></a></p> <p class="cleared rtejustify" style="clear: both;"><img src="/files/images/fokker-dvii/fokkerdvii6761dnp1.jpg" id="image-3037-_original" alt="" /></p><div id="panel" title="Page Width Resizer"><div id="plus"> </div><div id="minus"> </div></div><p> </p><div title="Page Width Resizer" id="panel"><div id="plus"> </div><div id="minus"> </div></div><p> </p></div></div></div><div class="field field--name-field-tags field--type-taxonomy-term-reference field--label-above"><div class="field__label">Tags:&nbsp;</div><div class="field__items field-items"><div class="field__item field-item even" rel="dc:subject"><a href="/taxonomy/term/47" typeof="skos:Concept" property="rdfs:label skos:prefLabel" datatype="">Fokker DVII</a></div></div></div><div class="field field--name-field-attached-gallery field--type-entityreference field--label-hidden"><div class="field__items field-items"><div class="field__item field-item even"><article about="/projects/fokker-dvii-build" typeof="sioc:Item foaf:Document" class="ds-1col node node--media-gallery node-teaser mg-gallery mg-teaser view-mode-teaser node--teaser node--media-gallery--teaser clearfix">
<div class="field field--name-title field--type-ds field--label-hidden"><div class="field__items field-items"><div class="field__item field-item even" property="dc:title"><h2 class="node__title"><a href="/projects/fokker-dvii-build">Fokker DVII Build Gallery</a></h2></div></div></div><div class="field field--name-field-lead-image field--type-image field--label-hidden"><div class="field__items field-items"><div class="field__item field-item even"><a href="/projects/fokker-dvii-build"><img typeof="foaf:Image" src="http://thevintageaviator.co.nz/sites/default/files/styles/teaser_220/public/images/fokker-dvii-build/blue-max-build-100.jpg?itok=bAmzmXq7" width="220" height="160" /></a></div></div></div><div class="field field--name-media-gallery-description field--type-text-long field--label-hidden"><div class="field__items field-items"><div class="field__item field-item even"><p>Images of the Fokker DVII Build process</p>
</div></div></div><div class="field field--name-node-link field--type-ds field--label-hidden"><div class="field__items field-items"><div class="field__item field-item even"><a href="/projects/fokker-dvii-build" class="">Read more</a></div></div></div></article>
</div></div></div>Sun, 05 Apr 2009 10:11:37 +0000dan218 at http://thevintageaviator.co.nzFokker DVII Build Storyhttp://thevintageaviator.co.nz/projects/fokker-dvii/build-story
<div class="field field--name-body field--type-text-with-summary field--label-hidden"><div class="field__items field-items"><div class="field__item field-item even" property="content:encoded"><p class="rtejustify"><a href="http://thevintageaviator.co.nz/sites/default/files/images/fokker-dvii-build/blue-max-build-001.jpg" class="colorbox embedded-image" rel="content-images" title="Blue Max Build 001" style="float:right;"><img align="right" alt="" id="image-2990-thumbnail" src="/sites/default/files/styles/medium/public/images/fokker-dvii-build/blue-max-build-001.jpg" /></a><br /><span class="dropcap">T</span><b>here are as many reasons for taking on a project as there are methods to complete it. In the case of movie props... one source is the original article, another is to build a replica. </b><b>Time constraints and deadlines sometimes dictate the style and construction methods.</b> In the case of the Fokker DVII built for “The Blue Max” film. We can safely say the aircraft was built to an airworthy standard in a very short period of time! At the Vintage Aviator Ltd we are responsible for the operation and maintenance of a number of WW1 aircraft, including the Fokker DVII built in France for the 1966 film “The Blue Max”. The original constructors of this machine, Rousseau Aviation, Dinard Airport France, did a marvelous job at creating a flying aircraft replica for the film, however years of use and several owners later have taken it’s toll. This aircraft was airworthy when it arrived here in New Zealand but we wanted to restore it and add more details that would make it a more accurate replica.</p>
<p class="rtejustify">After having flown the DVII for several hours here in NZ we became aware of its shortcomings rather quickly, it just didn’t perform like the legendary fighter it represented. The airplane was heavy and the engine seemed a bit tired and the fabric covering was clearly a quick attempt at “fake” printed lozenge. Each pilot that had the chance to fly it liked it, but all made the same general comments “It feels heavy”, “It wont climb”, and “I cant catch the SE.5a or the Camel”...</p>
<h3 class="rtejustify">Face Lift</h3>
<p class="rtejustify"><span class="dropcap">T</span><b>he decision was quickly made to give the DVII a bit of a face lift. After all of our airshow commitments had passed we started to disassemble the aircraft and see what could be done to improve its performance and looks. </b>Since this airplane is a replica that doesn’t use an original engine nor original construction we had a great deal of leeway on what we could do.<br /><br /><a href="http://thevintageaviator.co.nz/sites/default/files/images/fokker-dvii-build/blue-max-build-002.jpg" class="colorbox embedded-image" rel="content-images" title="Lower wing undergoing inspection and repair" style="float:left;"><img align="left" alt="" id="image-2991-medium" src="/sites/default/files/styles/medium/public/images/fokker-dvii-build/blue-max-build-002.jpg" /></a><br />
In all fairness to the original constructors, this aircraft has been around for a while and has been used in several films, it served it’s purpose and did a fantastic job. The sheer fact the airplane has been in service for nearly 45 years could add to it’s lack of performance, propellers have been changed, the engine was starting to get tired, repairs have been made and the airframe was getting heavier as planes seem to do when they age! With the dismantled aircraft in our workshop we could remove the fabric and inspect all of the individual components. The construction slightly different to the original, ribs are made of thin plywood and the spars appear to be solid laminated lengths of spruce. The trailing edge has been cut out of timber rather than the original wire trailing edge that gives many Fokker aircraft that distinctive “scalloped” look. Wing tip bows are made of massive chunks of ash that have been steamed to shape them. In an effort to make sure this aircraft was back in the air before too long we set a deadline to “return it to service” so that we didn’t end up rebuilding everything or spending too much on it! It was quickly determined that the wings were in good shape and only minor repairs were needed. We removed some weight from the wingtip bows and sealed the entire structure to protect it from moisture.<br /><br /><br />
</p>
<h3 class="rtejustify">Materials</h3>
<p class="rtejustify"><a href="http://thevintageaviator.co.nz/sites/default/files/images/fokker-dvii-build/blue-max-build-016.jpg" class="colorbox embedded-image" rel="content-images" title="This heavy construction was replaced with 4130 streamlined tube at a huge weight savings" style="float:right;"><img align="right" alt="" id="image-2998-thumbnail" src="/sites/default/files/styles/medium/public/images/fokker-dvii-build/blue-max-build-016.jpg" /></a><br /><span class="dropcap">W</span><b>hen building any aircraft raw materials are of prime importance. The selection of materials based on strength weight and availability.</b> It became apparent that during the construction of the DVII the selection of materials to build the aircraft out of must have been strongly influenced perhaps dictated by the time frame. For instance the decision to make “streamlined tube” out of several round tubes had to have been because the builders could not source appropriate sized streamlined tube in a hurry. This method of construction added a huge amount of weight to the plane and was far more labor intensive. The cabane strut “tripods”, interplane struts and landing gear struts were all built up of many pieces of tubing rather than single streamlined tubes. These make shift streamlined tubes were built up of at least two whole round tubes of different sizes and then tacked together with two more sections of round tube split in half! Each conglomerate of steel tubing was then wrapped with fabric to give it a finished streamlined airfoil shape. These parts alone were several times heavier than a similar part made out of a single sreamlined tube. In order to replace these built up struts we positioned the overhauled wings in place on the fuselage and rigged the airplane, partially fabricating the new struts in situ. </p>
<p class="cleared rtejustify" style="clear: both;"><a href="http://thevintageaviator.co.nz/sites/default/files/images/fokker-dvii-build/blue-max-build-089.jpg" class="colorbox embedded-image" rel="content-images" title="&lt;p&gt;Newly recovered fuselage, note the printed fabric rather than the painted on lozenge it previously had.&lt;/p&gt;&#10;" style=""><img alt="" id="image-3030-preview" src="/sites/default/files/styles/screensize/public/images/fokker-dvii-build/blue-max-build-089.jpg" /></a></p>
<h3 class="rtejustify"><br />
Remaking Authenticity</h3>
<p class="rtejustify"><a href="http://thevintageaviator.co.nz/sites/default/files/images/fokker-dvii-build/blue-max-build-015.jpg" class="colorbox embedded-image" rel="content-images" title="&lt;p&gt;Just some of the parts removed or replaced, A total of nearly 400 lbs was removed!&lt;/p&gt;&#10;" style="float:left;"><img align="left" alt="" id="image-2997-thumbnail" src="/sites/default/files/styles/medium/public/images/fokker-dvii-build/blue-max-build-015.jpg" /></a><br /><span class="dropcap">T</span><b>he tail surfaces were also constructed out of materials that deviated a great deal from the original.</b> Since many sets of drawings and much research has been made into the Fokker construction it would be foolish to imply the builders were simply not aware of the original construction. The original constructors also mentioned that they had access to one of the surviving original Fokker DVII’s housed in the French Musee de l’Air at Chalais Meudon. Once the tailplane was stripped of fabric we decided to see why it was so heavy. We have already restored seven Fokker Triplanes and have a tremendous experience with Fokker tailplanes. The DVII tailplane just felt wrong! The easiest way to check the material would be to cut into it and see how thick the steel tube was....... after one slice we discovered it was more like pipe!</p>
<p class="rtejustify"><a href="http://thevintageaviator.co.nz/sites/default/files/images/fokker-dvii-build/blue-max-build-018.jpg" class="colorbox embedded-image" rel="content-images" title="David Cretchley weighing the ballast we removed from the nose of the aircraft" style="float:right;"><img align="right" alt="" id="image-2999-thumbnail" src="/sites/default/files/styles/medium/public/images/fokker-dvii-build/blue-max-build-018.jpg" /></a><br />
This would explain the huge lead weights attached to the engine mount, these were needed to counterbalance the heavy tail and maintain a reasonable center of gravity. We were shocked when we removed the weights and set them on our scales. The two weights totaled nearly two hundred pounds! Part of this was necessary to compensate for using a lighter more modern air cooled engine, a gipsy queen, instead of the heavier liquid cooled Mercedes engine which would have originally been used.</p>
<p class="rtejustify"><a href="http://thevintageaviator.co.nz/sites/default/files/images/fokker-dvii-build/blue-max-build-094.jpg" class="colorbox embedded-image" rel="content-images" title="New tailskid replaced the modern tailwheel that was fitted" style="float:left;"><img align="left" alt="" id="image-3034-thumbnail" src="/sites/default/files/styles/medium/public/images/fokker-dvii-build/blue-max-build-094.jpg" /></a><br />
A new tailplane was in order, some parts were reused and incorporated into our new chromoly structure. While we were working on the tail section we decided to install a proper tailskid in place of the tailwheel that was fitted. We knew that a tailskid must have been installed when the airplane was built, it appeared in the film with one, and all the mounting points and bungee attachments were already in place. Fitting a tailskid was easy.</p>
<h3 class="rtejustify">Structure</h3>
<p class="rtejustify"><a href="http://thevintageaviator.co.nz/sites/default/files/images/fokker-dvii-build/blue-max-build-036.jpg" class="colorbox embedded-image" rel="content-images" title="The entire fuselage was sandblasted inspected and repainted" style="float:right;"><img align="right" alt="" id="image-3011-thumbnail" src="/sites/default/files/styles/medium/public/images/fokker-dvii-build/blue-max-build-036.jpg" /></a><br /><span class="dropcap">M</span><b>oving forward from the tail, we found the structure to be well preserved and in incredibly good condition, </b>all that was required was stripping the paint and removing some unnecessary turnbuckles. The Fokker style fuselage is of welded steel construction, having wire bracing in each “bay”. In this replica each wire brace had two turnbuckles, we elected to liberate some of these turnbuckles for future use elsewhere and to reduce weight once again. The steel structure was stripped and repainted and all new hardwire bracing installed with half as many turnbuckles. The floorboards were heavy old oil soaked fiberboard that was beginning to delaminate so we replaced these with aircraft plywood and thin aluminum “heel plates” to help prevent the wood from wearing away. The seat, control stick assembly and rudder bar was a complete unit removed from a Stampe biplane, this unit was restored and reinstalled after minor modification to the brake master cylinders.</p>
<p class="cleared rtejustify" style="clear: both;"><a href="http://thevintageaviator.co.nz/sites/default/files/images/fokker-dvii-build/blue-max-build-040.jpg" class="colorbox embedded-image" rel="content-images" title="Luckily we had an original Mercedes engine to copy details from" style=""><img alt="" id="image-3014-preview" src="/sites/default/files/styles/screensize/public/images/fokker-dvii-build/blue-max-build-040.jpg" /></a></p>
<h3 class="rtejustify"><br />
Accessories</h3>
<p class="rtejustify"><a href="http://thevintageaviator.co.nz/sites/default/files/images/fokker-dvii-build/blue-max-build-095.jpg" class="colorbox embedded-image" rel="content-images" title="&lt;p&gt;Engine details complete, the new gun m ounts are ready to recive replica &lt;a href=&quot;/projects/reproduction-guns/spandau-gun&quot;&gt;spandau&lt;/a&gt;'s&lt;/p&gt;&#10;" style="float:right;"><img align="right" alt="" id="image-3035-medium" src="/sites/default/files/styles/medium/public/images/fokker-dvii-build/blue-max-build-095.jpg" /></a><br /><span class="dropcap">I</span><b>n an effort to make the DVII look more authentic we installed a set of our reproduction aircraft guns</b><b>, in this case LMG 08/15 “Spandau” machine guns. </b>We removed the makeshift windscreen and added ammo chutes, fuel gauge, fuel filler and various doors and access panels that an original aircraft would have. Again to our amazement, this airplane had a huge fuel tank entirely made out of steel turn plate, it weighed a ton. We decided to make a lighter aluminum tank with a slightly smaller volume, this even gave the pilot more room for his legs.</p>
<p class="rtejustify"><a href="http://thevintageaviator.co.nz/sites/default/files/images/fokker-dvii-build/blue-max-build-045.jpg" class="colorbox embedded-image" rel="content-images" title="&lt;p&gt;The finished fiberglass nose, ready for paint&lt;/p&gt;&#10;" style="float:left;"><img align="left" alt="" id="image-3019-medium" src="/sites/default/files/styles/medium/public/images/fokker-dvii-build/blue-max-build-045.jpg" /></a><br />
Forward of the firewall we focused our efforts on cleaning up plumbing and wiring since the engine installation was functional and in fairly good order. Upon inspection only a few brackets showed distress form years of service, these were repaired by welding or replaced and the newly overhauled Gipsy queen set in place so that new cowlings could be made. The replica already had slightly modified cowls to hide the modern engine and disguise it looks, these could be improved on. We chose a late model Fokker Built aircraft to replicate, this necessitated making new cowlings with proper louvers and a reshaping of the fiberglass nose bowl. </p>
<p class="cleared rtejustify" style="clear: both;"><a href="http://thevintageaviator.co.nz/sites/default/files/images/fokker-dvii-build/blue-max-build-043.jpg" class="colorbox embedded-image" rel="content-images" title="&lt;p&gt;The finished Gipsy / &lt;a href=&quot;/projects/mercedes-engine/mercedes-engine-restoration&quot;&gt;Mercedes&lt;/a&gt; engine&lt;/p&gt;&#10;" style="float:left;float: left;"><img align="left" alt="" id="image-3017-thumbnail" src="/sites/default/files/styles/medium/public/images/fokker-dvii-build/blue-max-build-043.jpg" style="float: left;" /></a><a href="http://thevintageaviator.co.nz/sites/default/files/images/fokker-dvii-build/blue-max-build-044.jpg" class="colorbox embedded-image" rel="content-images" title="Fitting new side cowls and fokker style wingnuts" style="float:left;float: left;"><img align="left" alt="" id="image-3018-thumbnail" src="/sites/default/files/styles/medium/public/images/fokker-dvii-build/blue-max-build-044.jpg" style="float: left;" /></a><a href="http://thevintageaviator.co.nz/sites/default/files/images/fokker-dvii-build/blue-max-build-084.jpg" class="colorbox embedded-image" rel="content-images" title="The working exhaust made to look just like the Mercedes exhaust stack" style="float:left;float: left;"><img align="left" alt="" id="image-3027-thumbnail" src="/sites/default/files/styles/medium/public/images/fokker-dvii-build/blue-max-build-084.jpg" style="float: left;" /></a></p>
<h3 class="rtejustify">Heavy Steel Landing Gear</h3>
<p class="rtejustify"><br /><a href="http://thevintageaviator.co.nz/sites/default/files/images/fokker-dvii-build/blue-max-build-029.jpg" class="colorbox embedded-image" rel="content-images" title="&lt;p&gt;Very sturdy and quickly built parts show access holes cut with a torch!&lt;/p&gt;&#10;" style="float:right;"><img align="right" alt="" id="image-3004-thumbnail" src="/sites/default/files/styles/medium/public/images/fokker-dvii-build/blue-max-build-029.jpg" /></a><span class="dropcap">T</span><b>he last major item to overhaul was the landing gear. Like everything else, this was </b><b>heavy and made of steel. </b>Original Fokker landing gear was carefully designed to be both strong and lightweight. Instead of the original style riveted aluminum box section this landing gear was made of Steel with access holes cut with a torch! Now it may not have been pretty but it sure worked well. The entire landing gear and axle assembly was replaced and as a result a weight savings of nearly sixty pounds was realized. After building the more authentic Fokker style landing gear one could see why a simpler version was used, the aluminum box section was difficult to construct and certainly took much longer than the simple welded version, and in the end it is completely hidden by the large fairing between the wheels.</p>
<p class="rtejustify"><a href="http://thevintageaviator.co.nz/sites/default/files/images/fokker-dvii-build/blue-max-build-039.jpg" class="colorbox embedded-image" rel="content-images" title="New landing gear assembly built to Fokker drawings" style="float:left;"><img align="left" alt="" id="image-3013-thumbnail" src="/sites/default/files/styles/medium/public/images/fokker-dvii-build/blue-max-build-039.jpg" /></a></p>
<p class="rtejustify">Only with a replica aircraft could we have the leeway to experiment with restoration and reconstruction on this level. However, with the time constraints involved, TVAL had to discover methods of reconstruction that wouldn’t involve total rebuilding and painstaking hours of work. With the overall facelift that the Fokker DVII received, including quite a drastic weight loss with the tailplane, fuel tank and landing gear replaced, we became confident that this would increase the aircraft’s performance in the sky, not to mention more leg-room for the pilot! Now with brand new Spandau guns and printed fabric replacing the previous painted lozenge, the new Fokker DVII is surely close to it’s former glory as a renowned fighter of speed and maneouverability, surely capable of once again catching the Se5a and the Camel.</p>
<p><br />
</p>
<p> </p>
<p class="cleared rtejustify" style="clear: both;"><a href="http://thevintageaviator.co.nz/sites/default/files/images/fokker-dvii-build/blue-max-build-091.jpg" class="colorbox embedded-image" rel="content-images" title="Upper wing fitted" style=""><img alt="" id="image-3032-preview" src="/sites/default/files/styles/screensize/public/images/fokker-dvii-build/blue-max-build-091.jpg" /></a></p>
<p class="cleared rtejustify" style="clear: both;"><img alt="" id="image-3037-_original" src="/files/images/fokker-dvii/fokkerdvii6761dnp1.jpg" /></p>
<div id="panel" title="Page Width Resizer">
<div id="plus"> </div>
<div id="minus"> </div>
</div>
<p> </p>
<div id="panel" title="Page Width Resizer">
<div id="plus"> </div>
<div id="minus"> </div>
</div>
<p> </p>
</div></div></div><div class="field field--name-field-tags field--type-taxonomy-term-reference field--label-above"><div class="field__label">Tags:&nbsp;</div><div class="field__items field-items"><div class="field__item field-item even" rel="dc:subject"><a href="/taxonomy/term/47" typeof="skos:Concept" property="rdfs:label skos:prefLabel" datatype="">Fokker DVII</a></div></div></div><div class="field field--name-field-attached-gallery field--type-entityreference field--label-hidden"><div class="field__items field-items"><div class="field__item field-item even"><article about="/projects/fokker-dvii-build" typeof="sioc:Item foaf:Document" class="ds-1col node node--media-gallery node-teaser mg-gallery mg-teaser view-mode-teaser node--teaser node--media-gallery--teaser clearfix">
<div class="field field--name-title field--type-ds field--label-hidden"><div class="field__items field-items"><div class="field__item field-item even" property="dc:title"><h2 class="node__title"><a href="/projects/fokker-dvii-build">Fokker DVII Build Gallery</a></h2></div></div></div><div class="field field--name-field-lead-image field--type-image field--label-hidden"><div class="field__items field-items"><div class="field__item field-item even"><a href="/projects/fokker-dvii-build"><img typeof="foaf:Image" src="http://thevintageaviator.co.nz/sites/default/files/styles/teaser_220/public/images/fokker-dvii-build/blue-max-build-100.jpg?itok=bAmzmXq7" width="220" height="160" /></a></div></div></div><div class="field field--name-media-gallery-description field--type-text-long field--label-hidden"><div class="field__items field-items"><div class="field__item field-item even"><p>Images of the Fokker DVII Build process</p>
</div></div></div><div class="field field--name-node-link field--type-ds field--label-hidden"><div class="field__items field-items"><div class="field__item field-item even"><a href="/projects/fokker-dvii-build" class="">Read more</a></div></div></div></article>
</div></div></div>Sun, 05 Apr 2009 10:11:37 +0000dan217 at http://thevintageaviator.co.nz